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Gutfleisch AdvMater 2011
Gutfleisch AdvMater 2011
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Magnetic Materials and Devices for the 21st Century:
Stronger, Lighter, and More Energy Efficient
Oliver Gutfleisch,* Matthew A. Willard, Ekkes Brück, Christina H. Chen,
S. G. Sankar, and J. Ping Liu
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Figure 1. (left) Electric power generation in the United States by source for 2007. (right) Residential electricity consumption since 1949. Electric losses
include energy lost from generation, transmission, and distribution. Data from Ref. [4].
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materials and devices. Equally important to sustainable invest-
ment in electricity sustainability is developing higher energy of free space and Ms is the saturation magnetization.
efficiency for power conversion. Advanced permanent and soft Recently, there is a much revived interest in various types
magnet materials provide high efficiency and reliability and of high-performance permanent magnets based on rare-earth
compact, low cost, and low maintenance solutions for renew- intermetallic compounds. This is triggered by, for example, the
able energy technologies, including wind turbines, hydroelec- growing demand for energy efficient technologies in which
tric power generators, and wave power buoys. these magnets often play a pivotal part. Generally, the major
driving force for research and development of rare-earth perma-
nent magnets (RPMs) is the need for maximized energy densi-
2. Hard Magnetic Materials ties at various operating temperatures. Most importantly, this
includes less Dy-containing Nd2Fe14B-type magnets with much
During the twentieth century, several permanent magnet mate- improved temperature stability for electromotor applications at
rials were discovered. Techniques to effectively manufacture around 450 K,[9] Pr2Fe14B-type magnets for applications at 77 K
these magnets have been established.[8] Device designs using together with high Curie temperature (Tc) superconductors,[10]
such magnets in various active and passive applications have and a new generation of SmCo 2:17-type magnets for applica-
been successfully exploited. The energy product, which is a tions at temperatures exceeding 670 K.[11,12] It also includes
key figure of merit of permanent magnets, has been enhanced, magnetic-power MEMS,[13–16] for example, a high-speed perma-
starting from ≈1 MGOe for steels discovered during the early nent magnetic generator, which require highly textured, thick
part of the century, increasing to ≈3 MGOe for hexagonal fer- RPM films.[17] Nowadays, emphasis of research is on the con-
rites, and finally peaking at ≈56 MGOe for neodymium-iron- trol of microchemistry and structure of grain boundary phases
boron magnets during the past ten years. With this, almost and internal interfaces, which are crucial for the understanding
90% of the limit for the energy density, (BH)max, (based on the of the relevant coercivity mechanisms and the related critical
Nd2Fe14B phase) can be achieved in commercially produced sin- elementary magnetization reversal processes. Textured nano-
tered Nd-Fe-B grades. The historical evolution, spanning nearly composites could be the next generation of permanent mag-
100 years, of these permanent magnets is shown in Figure 2. nets. This would involve mastering the fabrication of intimately
At the time of writing, however, it appears that the search for mixed multiphase and well-oriented nanoscale magnets, which
novel hard magnetic compounds with higher remanent mag- cannot be done by conventional processing techniques.
netization, defined now as the relevant parameter, has some-
what stagnated and no further breakthrough is in sight. On the
other hand, only a small number of ternary and quaternary sys- 2.1. General Considerations for Permanent Magnetic Materials
tems have been investigated so far. The approach of nanocom- in Energy Applications
posites is the one that is currently the most actively pursued,
with particular emphasis on attempting to have the hard mag- Permanent magnetic materials used in electric machines per-
netic phase textured, as well as exchange-coupled with a soft form one basic function, which is to provide magnetic flux. This
magnetic phase; the latter phase has an intrinsic upper limit of function requires a saturation magnetization (4πMs in cgs units
or Js = μ0Ms in SI units) as high as possible and affordable, as
well as an appropriate coercivity. Figure 3 shows the saturation
magnetization versus intrinsic coercivity, iHc, for major soft and
hard magnetic materials. Most of the soft magnetic materials
have iHc << 1 kA m−1 and the hard magnetic materials have iHc
up to ≈2800 kA m−1 (≈35 kOe).
For permanent magnets, coercivity is the ability to resist
demagnetization, including field demagnetization from the
electric or magnetic circuit and thermal demagnetization from
the operating temperature. Coercivity is extremely important
for motor applications since these two demagnetization actions
occur continuously while motors are running. Two coercivity
parameters are used to grade the magnetic hardness: one is
intrinsic coercivity, iHc (or jHc), and the other is normal (or
technical) coercivity, Hc. The permanent magnets suitable for
such applications must have high coercivity and ideally iHc is
much higher than Hc, which allows the magnets to have linear
demagnetization induction (B) curve in the second quadrant.
Linear B curve is a very important characteristic that enables
the magnets to be stable during operation. Only three types of
Figure 2. Development in the energy density (BH)max at room tempera-
ture of hard magnetic materials in the 20th century and presentation of
permanent magnets shown in Figure 3 possess such capability:
different types of materials with comparable energy density (each magnet these are hard ferrites, Nd-Fe-B, and Sm-Co magnets. Four pairs
is designed so that at a reference point 5 mm from the surface of the pole, of demagnetization curves at room temperature are shown in
a field of 100 mT is produced). Figure 4 for those three magnets and for an Alnico magnet. As
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Figure 3. Polarization versus coercivity of soft and hard magnetic materials. The inset shows a closer look at high energy density NdFeB-type magnets
with various Dy-contents for applications from room temperature to 200 °C.
shown in Figure 4, Alnico has nonlinear demagnetization curves coercivity (Nd10Dy4)Fe80B6 magnets with 4 at% Dy substitu-
and it is not suitable for motor applications. Sm-Co type mag- tion for Nd were developed for such applications. As shown in
nets have a very good, linear B curve at room temperature and Figure 4(right), the Dy added Nd-Fe-B retains linear B curves at
retain the linear B curve in the temperature range of 300°C to temperatures up to about 175 °C. Most of commercially avail-
550 °C, depending on the alloy composition.[11,12,18,19] Nd-Fe-B, able hard ferrites do not have a linear B curve at room tempera-
plotted in Figure 4(left), is not a good candidate for motor appli- ture; however, that does not prevent ferrite from being used for
cations since a nonlinear B–H curve with a “knee” is shown on motor applications since ferrite has a unique positive tempera-
its B curve, which indicates instability of this magnet when it is ture coefficient of coercivity, as shown in Figure 5.[20] The iHc of
surrounded in the electric field at elevated temperature. High the ferrite magnet increases from 3.2 kOe at 0 °C to 5.9 kOe at
Figure 4. Demagnetization curves in the 2nd quadrant for four major permanent magnets (left) and at various temperatures for Nd-Dy-Fe-B used for
motors (right). The (BH)max at 25 °C is in the parenthesis. Reproduced with permission.[21]
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Figure 5. Magnetic properties of four magnets at up to 300 °C: energy product (BH)max versus T (left) and coercivity iHc versus T (right).[20] The (BH)max
at 25 °C is in the parenthesis. Reproduced with permission.[20] Copyright 2000, IEEE.
300 °C, making ferrite a relative good material for motor appli- corresponding dimensions for cylindrical magnets. The load
cations. With the exception of ferrite, all other magnets shown line intersects with the B curve (B vs H), and the crossing point
in Figure 5 have negative temperature coefficients of coercivity. of the two lines is the operating point of the magnet, Bd/Hd. Hd
There are other considerations for permanent magnetic is the demagnetization field and Bd is the induction B at Hd. The
materials for energy related applications, including the load operating points for different temperatures are listed in Table 2,
line for the magnets. The load line, also called the permeance and the points in the shaded cells are not suitable for motor
coefficient, is only related to the geometry of the magnet. Figure 6 applications since they are near the knees of the B–H curves,
shows the demagnetization curves at 25 to 200 °C in 25 °C where the magnet is vulnerable to demagnetization during
increments for an Nd-Dy-Fe-B magnet that can be used for the dynamic operation. One example can be used to explain a
hybrid vehicle motors. The figure also shows the load lines with load line shown in Figure 6: the disc magnet with the length
Figure 6. Demagnetization curves at 25 to 200 °C for an Nd-Dy-Fe-B magnet and the load lines with corresponding dimensions for cylindrical magnets.
Reproduced with permission.[21]
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∗ The operating points in the shaded cells are not suitable for motor applications.
over diameter ratio (L/D) of 0.15 has a load line with |Bd/Hd| = these magnets manufactured in China, Japan, USA, and Europe
0.2, and the operating point is 1.5 kG/7.9 kOe at 150 °C. This together with their value (US dollars (US$)) and price during
magnet is not stable when the operating temperature is higher the past decade are shown in Table 3. It is interesting to note
than 150 °C because the operating points are near or below the that almost 80% of this strategic material is actually produced in
knees of the B curves at 150 °C to 200 °C. For design engineers, China and manufacture in the US has ceased since 2004.
this thin magnet should not be used at temperatures higher The world market for permanent magnets was estimated at
than 125 °C if safety is a factor under consideration. ≈$8 billion in 2007 and is predicted to be $11 billion by 2010,
with 34% hard ferrite, 65% rare earth magnets, and 1% Alnico.
The growth rate of total permanent magnets is estimated to be
2.2. World Market for Permanent Magnetic Materials ≈12% annually.[22] The fastest growing market is for Nd-Fe-B-
based magnets with high energy product, which would capture
NdFeB magnets, in particular, have significantly impacted the 62% market share in 2010. The dominant growing area of per-
development of computer peripherals such as voice coil motors manent magnetic materials is the energy-related applications.
and actuators, both in down-sizing and in enhancing their per- Design, development, and manufacture of consumer elec-
formance characteristics. For example, in 1984, computer disk tronics goods, such as DVDs, iPods, cameras, sensors, and cell
drives of ≈10 MB size with random access time of over 60 ms phones, are taking place at a rapid pace. All these devices include
were the norm. Today, external hard drives of much smaller components that utilize permanent magnets, such as the vibra-
physical dimensions but with a storage capacity of a few hun- tory motor in a cell phone. High-energy magnets enable the
dred GB, running at speeds up to 7200 rotations per minute design of these miniaturized devices. Such a miniaturization
(rpm) and with seek times of ≈8 to 12 ms have become common. strongly impacts the reduction in electrical power consumed in
More importantly, these high-performance drives are available the operation these devices, either from the mains or through
at affordable costs. These extraordinary developments are partly the rechargeable batteries. Thus, these devices now operate at
attributable to the availability of magnets with energy products in high energy efficiencies. Large quantities of NdFeB magnets
excess of 50 MGOe. The production of NdFeB sintered magnets are used in the construction of battery-operated tools, magnetic
has steadily increased from about 6000 tons in 1996 to about resonance imaging (MRI) units, electric bicycles (EB), electric-
63 000 tons in 2008 (see Figure 7 and Table 3).[22] The volume of assisted vehicles (EAV), speakers, magnetic separation units,
Figure 7. Output of NdFeB permanent magnets during the past ten years (left)[22] and predicted percentage sales ($) for 2010 of the major permanent
magnets in the world (right).[23]
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Table 3. Output (in tons), sales value (in US$ × 108), and price (US$ per kg) of NdFeB sintered magnets in China, Japan, USA, and Europe from 2003
REVIEW
to 2008.[22]
etc. This market segment is shown in Table 4 for China. The their low price. Based on the sales data in Figure 7, we esti-
market can be divided into three groups; the first one is termed mate annual usage is ≈433 kilotons for ferrite magnets and
the high-tech; the second group as the traditional and the third ≈68 kilotons for Nd-Fe-B magnets. As described earlier, the
one as the low grade. It is interesting to note that the first group invention of ferrite in 1946 revolutionized the design of motors
has experienced a four-fold expansion while the second group and generators. Despite the low-energy product (less than 10%
(traditional) has nearly doubled during the past five years. of that of Nd-Fe-B magnets) today ferrite is still the choice
Today ferrite magnets have the largest share in terms of of many engineers because of its low price. For the motors
tonnage in energy-related applications, which is attributed to used for hybrid vehicles, Dy partially substitutes Nd in order
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to increase the coercivity (Hc) to a level sufficient for high- and/or output power per volume (of the machine) than when
temperature applications. The disadvantages of this are the using electromagnetic excitation, and (c) better dynamic per-
reduction in the energy density, (BH)max, caused by the antipar- formance than motors with electromagnetic excitation (higher
allel coupling between Dy and Fe in the (Nd,Dy)2Fe14B unit cell[24] magnetic flux density in the air gap)”.
and the rarity of Dy.[9] It is estimated that currently 97% of Dy In addition to the developments in the permanent magnets,
rare-earth metal supply worldwide (1200 tons in 2008) is of there has been a substantial progress in semiconductor elec-
Chinese origin.[25] Metal prices in 2009 show that Dy costs ≈8 tronics resulting in the availability of switching devices, such as
times as much as Nd metal.[26] In order to keep the cost as low MOSFETs (metal oxide semiconductor field-effect transistors)
as possible and energy product as high as feasible, different and IGBTs (insulated-gate bipolar transistors), which are used
applications use different grades of Nd-F-B-based magnets, as to commutate the motors. Further, developments in power elec-
indicated in the insert of Figure 3. Common perception usually tronics enable the design and manufacture of intelligent con-
is that Sm-Co is much more expensive than the Nd-Fe-B mag- trollers to operate electromechanical devices. Computer soft-
nets, since the Sm metal is more expensive than Nd and the ware tools employing finite-element analysis techniques have
production process for Sm-Co is more complex than that for assisted in rapidly prototyping electromechanical devices. Thus,
Nd-Fe-B. The raw material cost of Nd-Dy-Fe-B is ≈$20 per kg, the synergistic advances in these fields have enabled the rapid
higher than that for Sm-Co 2:17 metals, ≈$18 per kg, as listed growth of the permanent magnet motor industry.
in Table 5. The longer manufacturing process for Sm-Co makes The electromagnetic interaction between the magnetic flux
its price ≈15% higher than Nd-Dy-Fe-B’s; however, if a higher produced by a permanent magnet with a flux density, B, and
acceleration and a higher fuel efficiency (requires higher oper- the electrical current flowing through a surrounding coil of
ating temperature) for certain electric cars are the goals, Sm- length, L, and area of cross section, A, carrying current with a
Co could actually be an alternative (compare Figure 5 (left)). current density, j, results in the generation of torque τ = BjrAL,
Heavy rare-earth elements like dysprosium and to some extent where r is the length of the torque arm. Generally, the magnetic
terbium are key components in producing RPMs that show the flux is focused to interact effectively with the current through
required temperature stability for motor applications. Looking the use of a soft magnet, such as soft steel, placed within the
at the supply situation, a strategy and novel microstructures available space envelope.[32] During operation of a motor, eddy
for RPMs are required to reduce the use of Dy. Another impor- currents, hysteretic effects, and mechanical friction all con-
tant issue for the future is the recycling of RPMs, again to tribute to electric losses in the form of heat. The ratio between
ensure a stable supply of rare-earth metal sources. For this the mechanical power, Pmech, derived from running the motor
purpose, hydrogen-assisted processing of RPMs could be very at an angular velocity, ω, and the electrical power, Pelec, pro-
advantageous.[27–29] The hydrogen decrepitation process (HD)[30] vided into the motor is the efficiency, η, of the motor. Thus, η =
could be used in the recycling of SmCo5, Sm2(Co,FeCu,Zr)17, (Pmech)/(Pelec) = (τω)/(VI). In this expression, V is the voltage
and NdFeB-type magnets. The growth of electric vehicles and supplied to the motor that produces a current I. Torque versus
with increasing environmental legislation, which is likely to speed or torque versus current and the efficiency of the motor
demand better energy efficiency, and more resourceful use of describe the basic performance characteristics of a motor. The
materials including recycling, especially for automotive applica- design engineers have to a) maximize the flux density, B, by a
tions where “end of life” rules are already being implemented. suitable selection of the permanent magnet as well as the soft
Such measures can be justified in terms of environmental magnet material; b) maximize the interaction between the flux
impact (metal contamination of landfill sites), energy saving lines of the magnet and the current flowing through the sur-
(CO2 reductions), and resource depletion. rounding wire by optimizing the geometry of the device; and
c) minimize the losses due to eddy currents, hysteresis, and
frictional effects and, if necessary, find an effective means to
2.3. Torque and Efficiency withdraw the heat produced in the motor by e.g., mounting it
on a heat sink.
Gieras and Wing[31] point out that “the use of permanent mag- Gieras and Wing[31] compared the performance of a small
nets in the construction of electrical machines result in the fol- three-phase, four-pole, 1.5 kW, 50 Hz cage-induction motor
lowing benefits: (a) no electrical energy is absorbed by the field with that of a rare-earth permanent magnet (PM) brushless
excitation system and thus there are no excitation losses which motor. The full-load efficiency of the former is about 75% while
means substantial increase in efficiency; (b) higher torque that of the latter is nearly 88%. Thus, the induction motor
Table 5. Cost of raw materials of the two types of magnets (price based on July 2009 data).[26]
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Figure 8. Some advantages of a PM motor over an induction motor (IM). Reproduced with permission.[33]
draws nearly 2000 W of electricity and the PM motor draws many applications), the torque levels off at about 40 MGOe due
only 1704 W. The power savings is 296 W (or ≈15%) per motor. to the flux saturating the soft magnet that is used in the core.
Figure 8 shows some of the advantages of PM motor versus Simizu et al.[35] modeled the possibilities of designing brushless
induction motors. motors that are slotless and demonstrated the overwhelming
Honkura[34] demonstrates that the enhancement in the advantages of such designs in the further enhancement of
energy efficiency of a motor using rare-earth bonded magnet is torque using permanent magnets with potentially much
nearly 13% compared to a ferrite magnet motor, both operating improved high-energy products. A nearly 25% increase in the
at the maximum 400 W. The power density of the rare-earth torque of slotless, brushless permanent magnet motors over
permanent magnet motor was improved nearly twofold com- the slotted designs at about 60 MGOe, with a further poten-
pared to the ferrite motor. tial for such increases at higher-energy products of permanent
Electric vehicles, hybrid as well as plug-in, employ brush- magnets, have been predicted. Such designs will also result in
less motors. Proper design of such motors and the control an increase in energy efficiency. Further advantages of adopting
electronics is now a very important area of worldwide research high energy density magnets include higher torque-to-weight
and development. Key objectives are to a) design light-weight, ratio and reduction in noise and clogging.
high torque-to-weight ratio motors, b) achieve high efficiency
throughout the operational range, c) provide reliable control,
d) have rugged construction, e) provide low maintenance 2.4. Renewable Energy Generators: Wind Power and Magnetic
requirements, and f) supply the customers at low cost. It is also Materials
important to note that electric motors have high torque at low
speeds. In contrast, in internal combustion engines the torque Wind power is the fastest growing sector within the renewable
increases with speed until reaching an optimum power level and power generation. According to the World Wind Energy Associa-
then falls sharply. Thus, the permanent magnet motors offer a tion (WWEA), worldwide wind power capacity was 159 213 MW
number of benefits in furthering this mobility application. in 2009. As shown in Figure 9, wind power capacity has doubled
The possibilities of producing exchange-coupled perma- every three years in the last decade and is predicted to be around
nent magnets that offer the ability to exhibit energy products 1 900 000 MW in 2020.[36] A typical commercial wind turbine
in excess of ≈60 MGOe are being investigated by a number of consists of three blades connected to an asynchronous gener-
researchers around the world. However, in the case of conven- ator via a gearbox, thus transforming the mechanical power into
tional brushless, slotted motors (which are typically employed in electrical power. Asynchronous generators are constructed with
Figure 9. World total installed wind energy during the last decade (left) and country share of total capacity 2009. Reproduced with permission.[36]
Copyright 2010, World Wind Energy Association.
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soft magnetic lamination and iron and copper armature wind- 2918 kg of Nd-Fe-B. Apparently these proposed generators do
ings with the excitation field provided by copper coils. not fully utilize the high energy density of RPMs and therefore
Various wind turbine concepts have been developed and built a new design of PM generators is needed.
to maximize the energy harnessed, to minimize the cost, and to A 3 MW DD generator uses about 1.5 tons of RPMs; with
improve the power quality. Turbine concepts can be classified this the magnetic material represents a significant fraction of
with respect to the rotational speed, the power regulation, and the generator costs. Due to the consumer demand for low cost
the generator system. When considering the construction of the and long lifespan wind turbines, the permanent magnet com-
generator system, the turbines can be divided into direct-drive ponents represent an important trade-off between minimizing
and geared concepts. Generator systems can be separated into volume and protection against irreversible demagnetization due
the electrically excited (EE) machine and the permanent magnet to electrical faults or excessive heating. As demand increases
(PM) machine. The direct-drive generator system, especially for wind turbines and permanent magnet technologies emerge
direct-drive PM generator system, is superior in terms of the across industry sectors, a high demand for rare-earth magnets
energy yield, reliability, and maintenance.[37] Because of reliability could result in an increased material price and consequent chal-
issues and high servicing schedules of gearboxes, turbine pro- lenges for the economical feasibility.
ducers are developing direct-drive (DD) generators, which allow
power transformation without a gear. This has resulted in a shift
to synchronous generators because of the higher torque density 2.5. Energy Efficient Electric Machines: Electric and Hybrid
with the excitation field provided by the permanent magnet. New Vehicles
designs use Nd-Fe-B permanent magnets in the synchronous
generators (PMSG). As shown in Figure 10, four permanent The year 2009 was the 100th anniversary of the granting of the
magnet Nd-Fe-B generators are major components in advanced first US hybrid car patent or “Mixed Drive for Autovehicles”
wind turbines. A comparison of the new design with PM gen- (Figure 11) as it was described by the German inventor Henri
erators and a conventional generator yields drastic differences Pieper.[42] He says in his patent: “The invention… comprises
in volume and weight[38] as well as higher operating efficiency, an internal combustion or similar engine, a dynamo motor
higher torque density, 50% lower internal heat generation, and direct connected therewith, and a storage battery or accumu-
easier assembly and maintenance.[39,40] Compared to a geared lator in circuit with the dynamo motor, these elements being
system, the torque can be 100 times larger for a DD generator. cooperatively related so that the dynamo motor may be run as
Permanent magnet generators should have more advan- a motor by the electrical energy stored in the accumulator to
tages compared to conventional generators if the design of the start the engine or to furnish a portion of the power delivered
generators can be revolutionized by fully utilizing the high- by the set, or may be run as a generator by the engine, when
energy products of RPMs. The designs for the PM generators the power of the latter is in excess of that demanded of the set,
today are more or less similar to the configurations devel- and caused to store energy in the accumulator.” Pieper’s patent
oped for using hard ferrite magnets invented in 1946, which also included a rudimentary battery and engine management
revolutionized the design of inductors, transformers, motors, system. Unfortunately for Pieper, the year before his patent
and generators. RPMs, such as Sm-Co and Nd-Fe-B, have 8 was granted the assembly lines for the first inexpensive mass-
to 15 times the energy product compared to the ferrites. The produced car based on the internal combustion engine, the Ford
high-energy product should significantly benefit the inno- Model T, were under construction. By the 1930s, production of
vative design with tremendous performance enhancement. hybrids based on the Pieper system had ceased completely and
However, reports of multi-megawatt wind turbine showed the prevalence of the gasoline engine powered automobiles was
similar generator configurations, even when these very dif- cemented. Drivers controlled a magnetic-disc clutch that con-
ferent magnets ferrites and Nd-Fe-B would be used.[39] For nected the engine to a DC-motor generator, or dynamo, which
example, a 144-pole radial-flux PM generator would use 2948 kg was in turn connected to a gear-set that turned the rear wheels
of ferrite and a 144-pole radial-flux PM generator would use via chain drive. Now, a century later, hybrid electric vehicles
have re-emerged as a realistic alternative to the gas-only internal
combustion vehicle. The basic concept of a parallel hybrid is in
principle retained in today’s hybrids like the Toyota Prius (see
Figure 12).
Currently more than 1.5 million HEVs are on the road. Apart
from the worldwide environmental issues, this re-emergence
has been driven by the multiple advances in magnetic mate-
rials, electrical machine design, power electronics, and battery/
fuel cell technology. Electric or hybrid vehicles are being devel-
oped at an unprecedented pace[44] and their sales is expected
to increase dramatically in the next five years. One of the three
key components (besides the power control unit and battery) of
the hybrid vehicles is the PM-electric motor. As described ear-
lier, as is the case with PM generators, PM motors have many
Figure 10. Clipper’s 2.5 MW wind turbine with four permanent magnet advantages compared to induction motors including compact
generators. Reproduced with permission.[41] size, high efficiency, light weight, and high torque. According
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higher). The increased performance results from higher mag-
netic flux density in the working gap, estimated at ≈15% using
Ansoft’s Maxwell 3D computer modeling.[45]
It is not a straight-forward calculation to determine the per-
cent gain in motor efficiency resulting from the gain in energy
density of the magnet (BH)max. Different design is required as
the energy density of the magnet is increased because a higher
magnetic flux from the magnets can cause localized magnetic
saturation in certain areas if the design is not changed, and
this will not increase the torque and output power of the motor.
Many researchers reported their attempts to establish a method
Figure 11. Picture from Henri Pieper’s hybrid vehicle patent application
to estimate the torque of a motor.[46] These reports targeted dif-
from 1905.[42] ferent PM-rotor design rather than different energy densities of
the magnets. To estimate the motor’s improvement resulting
from the increase in energy density of the magnets, Ansoft’s
to Toyota, each hybrid Prius motor/generator uses ≈1.3 kg of
RMxprt computer software was used for analyzing a four-pole
Nd-Dy-Fe-B magnets.[43] The Toyota Hybrid System (THS) is a
surface-mounted PM motor,[45] as shown in Figure 14, using
power train combining the series hybrid system with the par-
the magnets with energy products of 23, 36, and a fictitious
allel hybrid system in order to maximize the benefits of both.
72 MGOe. The results are shown in Figure 15. When the same
Developing energy-efficient machines and hybrid vehicles
motor configuration is used, the starting torque (rpm = 0) and
demands permanent magnets with high performance as shown
output power are increased by 25−30% when (BH)max of the
in Figure 12.
magnet is increased from 36 to 72 MGOe. However, we have
One way to reach the goal of having the best fuel economy
to realize that a new design must be used when better mag-
and acceleration in the marketplace is to develop new permanent
nets are used, as described earlier. According to our estimation,
magnets with higher energy product and good thermal stability
the torque and output power with 72 MGOe magnets could be
at temperatures of 150–250 °C. Current hybrid vehicles use Nd-
increase by 70% compared to 36 MGOe magnets if an appro-
Dy-Fe-B magnets with (BH)max = 286.5 kJ m−3 (36 MGOe) and
priate design were be used. The torque and the output power of
intrinsic coercivity iHc = 2400 kA m−1 (30 kOe), stable at tem-
the new design using 72 MGOe magnets are shown in the top
peratures of about 180 °C. The value of iHc is very important
plots in Figure 15.
for such dynamic applications with elevated operating tempera-
ture because it is a key to resisting thermal demagnetization.
The performance of a PM motor is directly related to the mag-
netic flux provided by the permanent magnets. The Prius PM 2.6. Understanding and Controlling Microstructure
motor consists of an eight-pole rotor with high coercivity Nd- on the Nanoscale
Fe-Dy-B magnets inside. As shown in Figure 13, by arranging
the permanent magnets in a V-shape rather than a flat-shape, Various approaches are being examined in order to develop
the output power is increased from 33 to 50 kW (≈1.5 times) Dy-free Nd-Fe-B sintered magnets with high Hc for
and the drive torque is increased from 350 to 400 N-m (≈15% high-temperature applications.[47] In order to achieve this, it is
Figure 12. Prius’ generator and motor. Reproduced with permission from Toyota Motor Corporation.[43]
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Figure 15. The effect of the energy products of the magnets on a PM motor performance (all magnets have linear B–H demagnetization curves in the
second quadrant suitable for dynamic application). Torque vs speed (left) and output power vs speed (right).[45]
we deliver power.[55] These so-called “smart-grid” technologies, desire to increase the capability of these devices, induction gen-
using an array of advanced materials and devices, will provide erators housed in the nacelle must be given higher energy den-
more efficient, affordable, and sustainable energy use for the sities, which can be accomplished with improved soft magnetic
long term.[56] On the electricity generation side, soft magnetic materials and/or permanent magnetic materials if PM-motor
materials are especially important to maintaining an efficient designs are employed.
smart grid. For example, soft magnets have important roles in About 9% of the electricity generated is lost as heat during
wind energy technologies for generation using advanced induc- transmission and distribution.[59] While high voltage is neces-
tion motors and for conversion using power converters and/or sary for low losses in electrical transmission, DC transmission
power transformers. The architecture of modern wind turbines has lower losses than AC transmission. This is one reason that
include the generator in the nacelle (the enclosure attached to the smart grid has been discussed in terms of high-voltage
the rotor blades at the top of the turbine tower).[57,58] Due to the direct-current (HVDC) transmission. The expense of the HVDC
converter stations limits the implementation of this
more energy-efficient technology to transmission.
For this reason, the implementation of smart grid
technology will continue to require improved energy
efficiency for rectifiers, inverters, and transformers
using advanced soft magnetic materials. In present
devices, losses can be as low as 0.25% for some large
utility transformers, however, they may also be as
high as 15% for small consumer electronics “power
bricks”. In these applications, losses come from
a variety of sources including winding resistance,
eddy currents, stray fields, hysteresis, mechanical
losses, magnetostriction, and cooling systems. Of
these, eddy currents, hysteresis, and magnetostric-
tion are important soft magnetic parameters. Due
to their central role in these devices, soft magnetic
cores with lower core losses (including contributions
from hysteretic, magnetostrictive, and eddy current
Figure 16. Multiscale characterization of sintered Nd-Fe-B commercial magnets:
sources), higher magnetization, and improved cost
a) Backscattered electron contrast scanning electron microscopy (SEM) image effectiveness will be key components for improved
showing the hard magnetic Nd2Fe14B matrix grain well-separated by a thin Nd-rich energy efficiency.
intergranular phase (white contrast). b) Electron backscattering diffraction (EBSD) Soft magnetic materials come in many forms
image quantitatively showing the local variation in orientation of the different grains. ranging from soft iron, used in powder core induc-
c) optical Kerr microscopy showing the corresponding magnetic domain structure of tors, to silicon steel laminates and nanocrystalline
the same area. d) Transmission electron microscopy (TEM) image showing the amor-
or amorphous tape wound cores for transformers,
phous Nd-rich intergranular phase of about 1 nm thickness (from top left to bottom
right). Panels (e,f) show schematically and in atomic resolution the Nd2Fe14B matrix and to soft ferrites for electromagnetic interference
phase. Courtesy: T. G. Woodcock, IFW Dresden. (EMI) filters. The materials selection is important for
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Table 6. Magnetic properties for various commonly used soft magnetic materials.[60–62] Note: the Metglas alloy is amorphous and the Finemet
REVIEW
alloy is nanocrystalline. One Tesla exceeds the saturation magnetization for alloys marked with †.
Material μ0Ms (T) μmax (103) Hc (A/m) electrical resistivity Tc (°C) Pcm [60 Hz/1 T] magnetostriction
(ρe) (μΩcm) (W/kg) (λs) (ppm)
Fe49Co49V2 2.4 5–50 16–398 27 930 1.10 60
Soft Fe 2.16 10–50 4–80 10 771 20 −2
Fe 3%Si (GO) 2.0 0.5–5 6 48 745 0.84 7
Fe67Co18B14Si1 1.8 50 3.5 123 415 0.66 35
Metglas 2605CO
Ni50Fe50 permalloy 1.4–1.6 70 4–20 40–50 480 0.33 18
Fe73.5Si13.5Nb3B9Cu1 1.23–1.35 80 0.6–2.5 110 570 0.01 0–2
Finemet
Ni78Fe17Mo5 0.65–0.82 100–800 0.25–0.64 60 400 † 2–3
supermalloy
Mn-Zn ferrite 0.36–0.5 0.5–10 10–100 107–108 150–250 † ±5
Ni-Zn ferrite 0.25–0.42 0.01–1 14–1600 1011 120–500 † −20
and high frequencies (in conjunction with a move to GaAs or control have been active areas of research to provide more
SiC semiconductor active components). material options for better energy efficiency at higher operation
Size and weight reductions can be achieved for a given output frequencies.[72,73]
power requirement by increasing the operation frequency, as Great improvements in energy efficiency have been demon-
demonstrated in the schematic diagram from Figure 20.[70,71] strated for amorphous and nanocrystalline soft magnetic mate-
For instance, for a 500 W output power the volume of the rials. Due to the higher capital costs, this technology has not
transformer can be reduced by 50% when the frequency is received wide-spread use despite the availability of promising
raised from 6 to 60 kHz. As size and weight are extremely materials research during the past 20 years, and the lower life-
important for transportation applications (including electric cycle cost of using these cores.[66] The use of amorphous alloys
and hybrid cars and ships), exploitation of this effect would be has been shown to reduce transformer size and reduce acoustic
very advantageous, however, the losses of the system are not noise when compared to conventional Si-steels used in most
represented in this figure, and both the core and copper losses transformer cores today. Additionally, the improved energy effi-
increase with increasing frequency. Recent improvement in ciency of transformers using these materials results in reduced
soft magnetic performance by microstructure and composition carbon emissions considering the majority of electricity is gen-
erated from fossil fuels.
While recent soft magnetic materials developments have
resulted in advances in low-loss magnetic alloys, many of
these developments require sustained research investment to
improve the magnetization, magnetostriction, and extend their
upper operation frequency. Investment in the development of
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materials with larger magnetocaloric effects, which then can be antiferromagnetic to ferromagnetic). The lattice expansion due
operated in fields of about 2 T or less (i.e., fields that can be gen- to the addition of three interstitial hydrogen atoms per formula
erated by the aforementioned Nd-Fe-B-type permanent magnets). unit is about 1.5%.[92–94] The critical temperature can be increased
to up to 450 K, the average magnetic moment per Fe increases
from 2.0 μB to up to 2.2 μB and the field- or temperature-induced
4.1. La(Fe,Si)13 and Related Compounds phase transition is found to be of first-order for all hydrogen
concentrations. This all results for a certain Si percentage in an
The Fe-rich compounds La(Fe,Si)13, with the cubic NaZn13-type almost constant value of the magnetic entropy change per mass
structure, possess magnetic ordering temperatures between unit over a broad temperature range (Figure 22).
200 and 262 K and exhibit typical invar-type behavior.[81,82] Material processing will be somewhat more elaborate than
Due to the sharp first-order magnetic-ordering transition, for simple metal alloys, however La is the cheapest of the rare-
several groups have reported a large magnetocaloric effect earth elements so these materials should be cost-effective. Due
for this class of compounds,[83,84] which is enhanced when to the above described changes in lattice parameters caused
the materials are processed by rapid quenching and subse- by the phase transitions and/or hydrogenation, the material
quent annealing.[85–87] Above the Curie temperature Tc, an will potentially have long-term cycling problems because the
itinerant-electron metamagnetic (IEM) transition is induced by polycrystalline material may become granular with use. This
an external magnetic field. The IEM transition occurs due to can have distinct influence on the corrosion resistance of the
the change in the density of states at the Fermi level under the material and thus on the lifetime of a refrigerator and therefore
action of the magnetic field. Both transitions to the ferromag- must be investigated. Very recently, it could be demonstrated
netic state are accompanied by a sizable volume change of about that powderized bulk materials and melt-spun particles can be
1%.[88] In real materials, the lattice parameter can be modified hot-compacted to a porous morphology. The porous structure is
physically by applying external pressure or chemically by the much more tolerant to the huge magnetoelastic effects related
addition of substitutional or interstitial alloying elements.[89] to the first-order-type transitions and retains their mechanical
To increase the magnetic-ordering temperature without signifi- integrity over hundreds of cycles.[96] Only a slight decrease in
cant loss in the magnetic moment, one may replace some Fe by the adiabatic temperature change compared to the conventional
other magnetic transition metals. The compounds La(Fe,Co)13– bulk material was observed and, with this, one of the major
xAlx and La(Fe,Co)13–xSix with x ≈ 1.1 and therefore a very high obstacles for application can be regarded as being overcome.
transition metal content show a considerable magnetocaloric
effect near room temperature.[90,91] This is achieved with only
a few percent of Co and the Co content can easily be varied to 4.2. MnAs-Based Compounds
tune the critical temperature to the desired value, however, near
room temperature the values for the entropy drop. MnAs exists in two distinct crystallographic structures.[97] At
Further improvement in the magnetocaloric effect can be low- and high-temperature the hexagonal NiAs structure is
achieved by expanding the crystalline lattice, thereby influ- found and for a narrow temperature range from 307 to 393 K
encing the character of the direct exchange interaction (from the orthorhombic MnP structure exists. The high-temperature
transition in the paramagnetic region is of second-order.
The low-temperature transition is a combined structural and
ferro-paramagnetic transition of first-order with large thermal
20
Gd metal
LaFe11.4Si1.6H
LaFe11.4Si1.6H1.5
15
LaFe11.4Co0.5Si1.1
LaFe11.2Co0.7Si1.1
-ΔS (J/kg K)
10
0
260 280 300 320 340
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phase transition. Because of the small size of the thermal hys- 40
teresis (less than 1 K), the magnetization process can be consid- Gdmetal
ered to be reversible in temperature. Variation of the Mn:Fe ratio MnFeP 0.45As0.55
may also be used to further improve the MCE. More recently, a MnFeP 0.5As0.3Si0.2
30
large MCE was observed in the compound MnFeP0.5As0.3Si0.2 at MnFeP 0.5Si0.3Ge0.2
room temperature (see Figure 24).[124] After replacing all As, a
MnFeP 0.5As0.5
Table 7. Comparison of different potential magnetocaloric materials. Gd is included as reference material ([d] means direct measurement, [c] is calcu-
lated from a combination of measurements). The costs may strongly fluctuate due to market demands and quality of starting materials. Reproduced
with permission.[80] Copyright 2005, Institute of Physics.
Material T range (K) ΔSmax (2T) (J kg−1 K−1) ΔT (2T) (K) TC (K) Cost ∋/kg Density (x103 kg m−3) Ref.
Gd 270–310 5 5.8[d] 293 20 7.9 [79]
[d]
Gd5Ge2Si2 150–290 27 6.6 272 60 7.5 [134]
La(Fe,Si)H 180–350 19 7[c] 300 8 7.1 [87,88]
MnAs 220–320 32 4.1[d] 287 10 6.8 [101]
MnNiGa 310–350 15 2[c] 317 10 8.2 [116]
MnFe(P,As) 150–450 32 6[d] 292 7 7.4 [134]
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40 Acknowledgements
Gd
35 ΔB: 0 - 2 T
Gd5Ge2Si2 O.G. thanks the DFG, BMBF, EU, and various
30 Gd5Ge2Si2 optimal industrial partners for their financial support in the
past twelve years to his research effort in advanced
25
Mn1.1Fe0.9P0.5As0.5
functional magnetic materials. M.A.W. thanks
-ΔSm(J/K-kg)
applications and improved and innovated magnetic materials Received: June 14, 2010
will play an even more important role in energy solutions. They Published online: December 15, 2010
contribute to saving electric power and reducing CO2 emissions
in multiple ways. For example, the conversion of electrical
energy into mechanical work and vice versa is done using elec-
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